Three-dimensional self-supporting lace article

ABSTRACT

Three-dimensional, self-supporting lace embroidery article, and method of manufacturing same, wherein the article is made up of a plurality of lace embroidery panels consisting of physical embroidery lines of varying thickness and in an ornamental arrangement produced on an embroidery machine utilising machine readable code, wherein the embroidery panels are joined at predetermined locations to form the three-dimensionally shaped article, and wherein predetermined ones of said embroidery lines are disposed to provide a self-supporting structural lace framework or lace lattice grid.

FIELD OF THE INVENTION

This invention relates to lace embroidery, and more particularly to three-dimensional lace embroidery.

BACKGROUND TO THE INVENTION

Traditionally, embroidery has been practised on essentially two dimensional works to enhance the appearance of fabrics, clothing and similar articles, creating a relief pattern or image on a textile substrate. Embroidery may be performed by hand or by machine. Modern embroidery machines utilise machine readable code to autonomously create an embroidery pattern on a sheet of fabric material, eg an embroidered table cloth. The code is cut based on embroidery patterns.

Lace articles are somewhat related to embroidery articles, the main distinction being the absence of a carrier substrate, eg cloth, and the consequential presence of material voids of varying shape and size within a lattice of laced thread. Lace articles can be hand crafted using crochet hooks, knitting needles or a tatting shuttle, and machine-made nets can be embroidered to give patterned laces, using specialised lace embroidery machines. Both embroidery and lace works (articles) are used in handy crafts, clothing and other ‘textile’ applications.

It has been commonplace to apply embroidery (and lace) onto two-dimensional, planar or sheet-like products, and shaping these into simple three-dimensional articles having simple curvatures, such as bowls, cups and similar. In the case of lace bodies, the 3D-shape is made permanent by the use of suitable chemical or organic agents which are sprayed or otherwise impregnated onto the lace article whilst on a mould. When dry, these chemical agents, eg starch, provide stiffness to the 3D-lace sheet.

Previous attempts to produce complex-curved, three-dimensional embroidery and lace articles have been labour intensive processes. As it is difficult to embroider a finished three-dimensional article, one known solution in manufacturing complex-curved 3D embroidery articles has been to first embroider individual fabric pieces and then assemble the article from the fabric pieces.

U.S. Pat. No. 4,073,299 describes a method of creating a three dimensional embroidered article. The steps involved include producing a number of paper pattern pieces and joining the paper pieces to resemble the curved-surfaces article which is to be made, manually drawing the desired embroidery design or pattern (lines) on the paper article and disassembling the paper article. The paper pattern pieces, including the embroidery design, form the basis of patterns for the finished article. The patterns are used to cut fabric pieces which are then embroidered individually and sewn together at the seams to form the three-dimensional embroidered article. U.S. Pat. No. 4,073,299 indicates that this method can be used to produce more complex structures than a dome-shaped article such as a brassiere cup, eg gloves, furniture sundries for home use etc.

It will be immediately appreciated that the use of paper-based embroidery pattern creation for more intricate three-dimensional structures is extremely time consuming and difficult to achieve, in particular in creating decorative figurines. More relevant, however, is that the method of U.S. Pat. No. 4,073,299 will not invariably be suitable in the creation of three-dimensional lace bodies consisting solely of embroidery stitch lines, similar to wire figurines and similar ornamental objects, that are self-supporting, where consideration of continuity of embroidery patterns, which the method of U.S. Pat. No. 4,073,299 seeks to provide, is but one of the aspects in creation of a self-supporting structure.

It is desirable for the present invention to provide an alternative method of creating three-dimensional lace articles which is less time consuming to implement and which may be used to create self-supporting three-dimensional lace embroidery structures.

SUMMARY OF THE INVENTION

According to one aspect, the present invention provides a method for producing a three-dimensional, self-supporting lace (embroidery) article, the method including:

creating an image of embroidery lines on each one of and defining a plurality of embroidery panels that together make up or define a three-dimensional article;

transposing, preferably directly, the embroidery line images into machine readable code;

producing physical embroidery lines and embroidered panels by embroidering one or more water or otherwise soluble backing sheets using an embroidery machine adapted to read the machine readable code, wherein at least some of the physical embroidery lines are devised to form a support lattice structure or grid of the article;

joining predetermined points and/or portions along the physical embroidery lines within or between adjoining embroidered panels thereby shaping said three-dimensional embroidery article; and

at least partially dissolving said backing sheets thereby to obtain the self-supporting, 3D-lace embroidery article.

The invention thus utilises embroidery techniques in the manufacture of a 3-D lace article, in so far as a backing substrate is utilised to create the lace structures, and the backing substrate is subsequently removed by dissolving, thus leaving behind a lattice or grid with voids characteristic of lace works.

The method may also include one or more of the following steps:

creating a design for the three-dimensional article; or

dividing the design into a plurality of panels which are chosen such as to facilitate assembly of a 3-D, complex-curvature structure; or

creating a digital pattern for the plurality of panels.

In a preferred embodiment, the method also includes packing the three-dimensional article, once the panels are assembled but before dissolving the backing sheets, with a filler material to assist in forming and/or maintaining the shape of the article.

The method may further include further stiffening the article either by applying a water or otherwise soluble stiffening agent after the embroidery article has been formed, eg by surface coating embroidery strands using spraying techniques, by fully or partially impregnating the lace strands with such agent, or by incompletely removing the stiffening agent contained in the backing sheets during dissolving thereof.

According to a second aspect, the present invention provides a three-dimensional, self-supporting lace embroidery article, the article including:

a plurality of lace embroidery panels consisting of physical embroidery lines of varying thickness and in an ornamental arrangement produced on an embroidery machine utilising machine readable code;

wherein the embroidery panels are joined at predetermined locations to form the three-dimensionally shaped article, and wherein predetermined ones of said embroidery lines are disposed to provide a self-supporting structural lace framework or lace lattice grid.

Some embroidery lines may also be located and shaped to transfer force applied to the article, eg due to the weight of one or more of the panels, to panels resisting on a support surface, eg lower panels, to enhance the articles overall stiffness.

The panel joins may be linear extensions of the lines of embroidery, such that the lines of embroidery lead into joining points and induce a simple or complex curvature into the panel.

The embroidery strands may advantageously be additionally stiffened by the presence of a suitable stiffening agent, eg starch or polymer based chemical agents, that can be applied, eg sprayed, onto the finished article, or included in a soluble backing sheet onto which the embroidery lines are applied.

According to another aspect, the present invention provides a kit for producing a three-dimensional self-supporting lace embroidered article, the kit including:

machine readable code for producing two or more embroidered lace panels; and

instructions for joining the two or more embroidered lace panels at predetermined locations such that joining the panels at the predetermined locations forms a three-dimensional self-supporting article.

The machine readable code may include two or more different instruction sets, such that the code sets may be used for different types of lace embroidery machines.

The instructions for joining the two or more panels may include instructions for joining the panels at one or more discrete locations. Alternatively, the instructions may include instructions for joining two or more panels along a portion of, or the entire length of, an edge of any given panel. Further, the instructions may include instructions for joining portions of a single panel to an adjacent portion of the same panel.

Preferred embodiments of the invention will now be described in more detail by reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a three-dimensional, self-supporting embroidered lace article consisting of a plurality of lace embroidery panels, in accordance with a preferred embodiment of the present invention;

FIG. 2 is a plan view of an embroidered lace panel used in the article shown in FIG. 1;

FIG. 3 is a plan view of another embroidered lace panel with figurative instructions for constructing a portion of the three-dimensional, self-supporting embroidered lace article of FIG. 1;

FIG. 4 is a plan view of two embroidered lace panels with figurative instructions for constructing a portion of the three-dimensional, self-supporting embroidered lace article of FIG. 1;

FIG. 5 is a plan view of three embroidered lace panels with figurative instructions for constructing another portion of the three-dimensional, self-supporting embroidered lace article of FIG. 1; and

FIG. 6 is another plan view of three other embroidered panels with figurative instructions for constructing yet another portion of the three-dimensional, self-supporting embroidered lace article of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to FIG. 1, there is shown a three-dimensional, self-supporting lace article, having the form or shape of a swan 10, in accordance with a preferred embodiment of the present invention. The swan 10 is constructed (assembled) from a number of individually formed, lace panels, such as panels 12 a and 12 b shown in FIG. 4, manufactured using embroidery techniques. The individual, embroidered lace panels are joined at predetermined points, identified in a set of instructions, as exemplified in FIGS. 4 and 5 and described below, to form the three-dimensional, self-supporting lace article 10.

It should be noted that the article 10 has lace embroidery lines of varying thickness (or width) and length that are interconnected as appropriate to define an ornamental, self-supporting three-dimensional “lattice” lace work without any underlying fabric, canvas or other substrate. The lattice lace work provides both an ornamentation pattern that creates the visual appearance of the object, eg the swan, whilst some of the lattice embroidery lines provide a “skeleton” structure thereby to create a self-supporting line object, similar to complex wire figurines.

In devising the lace pattern for a three-dimensional article, (eg swan 10 shown in FIG. 1), the article's exterior surface is firstly divided into a number of discrete zones, or panels, and a digital pattern for the embroidery lines and/or regions on each of the zones is created. The digital pattern may be created using suitable software, or by optically scanning pre-drawn panels to create a digital format of the panel. In crating the digital pattern, some of the lines will be devised to provide the abovementioned skeleton which itself is self-supporting and interlaces with otherwise purely ornamental embroidery lines. The digital format of the panels is used to create machine readable instructions for producing the individual lace panels with the assistance of software, such as Wilcom ES9.

FIG. 2 shows an embroidered lace panel 11 which can be joined with other panels (see FIGS. 3 to 6) to form the article. The panel itself is formed by firstly manually creating a basic shape (outline) with single run stitch shapes and then manually creating a more, ornamented, complex shape, locking in complex sections of the sections of the lace pattern until the panel is the required shape, design and strength. The lace work can be created using eg Rayon™ 40 weight thread or other types of thread used in lace works. The embroidery lines (stitches) are embroidered onto a heavy weight, hot water soluble sheet material, eg Aqua Film (“Romeo”), which is then trimmed to the outer contour of the individual lace panel.

The stitches in the embroidery lines are locked so that the embroidered lace panel will not fall apart once the stiffening agent in the Aqua Film is washed out, ie each panel can be individually handled. Equally, some of the embroidery stitch lines that will form part of the skeletal self-supporting lattice-work of the finished article may be further stiffened (beyond use of multiple, interlocking or superimposed embroidered lace lines) by impregnating with suitable stiffening agents (eg starch), thereby adding overall stiffness and securing weight transfer capability onto those panels of the article which provide a support base or part of the article.

Embroidered lace panel 11 can be produced on a conventional embroidery machine (not shown) in known manner. The instructions for producing the panel 11 are best provided in machine readable code, which is stored in a format which may be read by the embroidery machine. The code may be stored on a CD-ROM, diskette, memory card or other suitable device, as is known in the art.

In order to assemble the multi-panel article 10, corresponding predetermined points or locations are identified on each panel for joining one panel to another panel. These points are joined manually, or by machine eg stitched or sewn together, to achieve three-dimensional curvatures in the panel itself and/or in adjacent, joined-together panels. For example, FIG. 3 shows an embroidered panel on which are identified a number of joining points 16 which when drawn together and stitched securely induce a curvature in an out-of-drawing plane orientation.

FIG. 4 shows an example where separate panels 12 a and 12 b are joined to form a larger portion of the three-dimensional, self-supporting lace article shown in FIG. 1. The panels 12 a and 12 b are joined along a length of the edge of the panel 12 a, designated by a line 21 a, and the complementary edge of panel 12 b designated by a line 21 b which are to be stitched together. The two panels 12 a and 12 b are joined together either by hand or machine sewing along the length of the seam.

FIG. 5 shows an example where four panels 12 a, 12 b, 12 c and 12 d are to be joined together. The panels 12 b and 12 c are firstly joined at the point indicated by 18, and finally at position 22. Once panels 12 a and 12 b are joined, panel 12 d is joined to 12 a and 12 b at the edges indicated by lines 24 a and 24 b.

It will be appreciated that joining of adjacent panels may not only take place along an edge of the panels but equally within the panel. Use of point and/or seam length joining will depend on the nature of curvature to be achieved. For example FIG. 6 shows embroidered side panels 12 b, 12 c and base panel 12 e which are to be joined at discrete points 30 a, 30 b, 30 c, 30 d, 30 e, 30 f, 30 g, 30 h and 301, thereby forming a three-dimensional cup-like shape with an oval base (12 e) and perpendicular extending side panels (12 b, 12 c), reminiscent of a boat structure with a chesty ‘bow’ and curving ‘tail’, ie. the lower body of a swan when in the water.

Once all of the lace embroidered, Aqua Film panels have been created (eg on a small hooped embroidery machine) and joined according to the instructions in a manner similar to the one described above, the article may be packed with a filler material to assist in forming and maintaining the shape of the article during subsequent removal of the Aqua Film backing material. Dissolving of the backing sheet is achieved by immersing the article in hot water. Whilst it is possible to remove all of the backing sheet material, eg by multiple water bath immersions, the stiffness of the embroidery lines may be increased or augmented by preventing full washout of the Aqua Film material. On drying of the article, its self-supporting embroidery lattice lines will provide shape/from integrity, and the filler material may be removed.

A kit for constructing the three-dimensional, self-supporting lace article will include machine readable computer code for producing the embroidered lace panels, provided on a CD-ROM, and instructions for joining the embroidered panels which are produced on an embroidery machine capable of reading the code provided on the CD-ROM. It will also be appreciated that the CD-ROM may carry a number of different machine readable codes to enable use of the CD-ROM with different types of embroidery machine makes. Alternatively, the code may be provided on another form of computer readable medium such as a diskette or a memory card.

It will be appreciated that in another embodiment, the instructions may be provided on the computer readable medium and may be printed by the intended user of kit.

If the instructions are provided in paper form, the instructions may also include a form of copy protection, such as a watermark to prevent unauthorised copying of instructions. 

1. Method for producing a three-dimensional, self-supporting lace article, the method including: creating an image of embroidery lines on each one of and defining a plurality of embroidery panels that together will make up and define a three-dimensional article; transposing the embroidery line images into machine readable code; using the machine readable code in producing physical embroidery panels embodying the embroidery lines by broidering one or more water or otherwise soluble backing sheets using an embroidery machine adapted to read said machine readable code, wherein at least some of the physical embroidery lines are devised to form a support lattice structure or grid of the article; joining predetermined points and/or portions of the physical embroidery lines within individual and along adjoining embroidery panels thereby shaping a three-dimensional embroidered article; and dissolving said backing sheets thereby to obtain the three-dimensional, self-supporting lace article.
 2. The method of claim 1, further including the step of creating a digital pattern for the plurality of panels.
 3. The method of claim 1, further including packing the three-dimensional embroidered article with a filler material to assist in forming and/or maintaining the shape of the article.
 4. The method of claim 1, further including additionally stiffening the three-dimensional, self-supporting lace article either by applying a water or otherwise soluble stiffening agent after the embroidery article has been formed, or by incompletely removing stiffening agent contained in the backing sheets during dissolving thereof.
 5. A three-dimensional, self-supporting lace embroidery article comprised of a plurality of embroidered lace panels consisting of physical embroidery lines of varying thickness in an ornamental pattern produced on an embroidery machine utilising machine readable code, wherein predetermined points and/or portions of the physical embroidery lines within individual and along adjoining embroidery panels are joined to define the three-dimensional article with complex curves, and wherein predetermined ones of said embroidery lines are disposed to provide a self-supporting structural lace framework or lace lattice grid.
 6. The article of claim 5, wherein some of said embroidery lines are located and shaped to transfer force applied to the article to lace work sections resisting on a support surface.
 7. The article of claim 6, wherein at least some of the embroidery lines are impregnated with a stiffening agent.
 8. The article of claim 6, wherein at least some of the embroidery lines are surface coated with a stiffening agent. 